International Research Journal of Engineering and Technology (IRJET)
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A Review paper on alternate materials for Asbestos brake pads and its
characterization
Dr.R.Umamaheswara Rao1,G.Babji2
1 Associate professor, Department of Mechanical Engineering , GMR Institute of Technology, Rajam, A. P, INDIA
2 M.Tech Student, Department of Mechanical Engineering, GMR Institute of Technology Rajam, A. P, INDIA
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Abstract -Studying about alternate materials for
brake pads is necessary as the asbestos brake pads
causing the carcinogenic effects and these are phased
out. There are so many alternatives for asbestos are
investigated from different journals. In this review
paper some of the most suitable environment friendly
and best performed compositions are presented. Fibers
made up of agricultural wastes like banana peels, palm
kernel shells, palm wastes, rock wool, aramid fibers,
flax fibers etc are studied. Different alternatives for
filler materials, Different binders like phenolic resin,
epoxy resin are also studied and it effect on the
performance of brake pads are presented.
Formulations that are made by varying compositions of
filler, fiber, binder etc and possibility of replacing the
existing formulations and its effect on the physical and
tribological properties of the brake pad are studied.
Key Words: Asbestos, fiber, filler, binder, phenolic,
epoxy etc.
1. INTRODUCTION
A brake plays a vital role in any automotive vehicle so as to
slow down the vehicle or to stop the vehicle completely.
During the application of brake, friction between brake
pads and rotating disc causes to stop the vehicle by
converting kinetic energy of the vehicle into heat energy.
Therefore the brake pads should quickly absorb heat,
should withstand for higher temperatures and should not
wear. The brake pad material should maintain a
suciently high friction coecient with the brake disc, not
decompose or break down in such a way that the friction
coecient with the brake disc is compromised at high
temperatures and exhibit a stable and consistent friction
coecient with the brake disc. In past years asbestos is
used in brake pads. But asbestos causes carcinogenic
effects on human health. It leads to the investigation on
new materials particularly agricultural residues or wastes
are now emerging as new and inexpensive materials in the
brake pads development with commercial viability and
environmental acceptability for brake pad which
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possesses all the required properties. There are metallic,
semi metallic and organic brake pad materials.
Generally brake pad consists of a composition
of reinforced fibers ,binder, fillers, friction additives. All
these constituents are mixed or blended in varying
composition and brake pad material is obtained using
different manufacturing techniques. Reinforced fibers
increase mechanical strength to the friction material. The
purpose of a binder is to maintain the brake pads
structural integrity under mechanical and thermal
stresses. It holds the components of a brake pad together
and to prevent its constituents from crumbling apart.
Fillers in a brake pad are present for the purpose of
improving its manufacturability as well as to reduce the
overall cost of the brake pad. Abrasives and lubricants are
considered as friction additives, abrasives in a friction
material increase the friction cofficient. They remove iron
oxides from the counter friction material as well as other
undesirable surface lms formed during braking.
Lubricant stabilizes developed friction coefficient at high
temperature.
In the present review paper different environment and
healthy friendly alternative materials for asbestos brake
pads are provided and their preparation, properties etc
are studied. The materials varied are the filler materials
like dolomite, CaCO3 etc, some agricultural wastes are
studied to provide them as a fibers and binder also
changed like phenolic or epoxy resin.
2. LITERATURE REVIEW
K.K. Ikpambese et-al[1] prepared brake pad material using
natural fiber called palm kernel fibers (PKFs) for its eco
friendly nature with CaCO3, graphite and Al2O3 as other
constituents. Epoxy resin is used as binder. Composition of
40% epoxy-resin, 10% palm wastes, 6% Al2O3, 29%
graphite, and 15% calcium carbonate gave better
properties than other composition. The results were
compared with commercial asbestos, palm kernel
shells.Results shown that PKF can be suitable for
replacement of asbestos brake pads with epoxy resin as a
binder.
C.M.Ruzaidi et-al[2] incorporated the waste material, palm
slag as filler material along with CaCO3 and dolomite in
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brake pad material to increase the performance to cost
ratio. The final composition is made using steel fibres,
phenolic resin and other friction additives. Results shown
that even though the dolomite brake pad composite had
the highest strength, it showed poor wear behavior
compared to calcium carbonate and palm slag. Thermal
stability of the palm slag material shown the better
performance compared to other two filler material in the
range of 50oC to 1000oC. It is proven that phenolic resin
cannot be used at high temperatures since curing of
binder starts at a temperature of 150oC caused for the
weight loss.
C.M.Ruzaidi et-al[3] has studied mechanical properties
and wear behavior of brake pads produced from palm slag.
In this paper the composite formed after the hand
hydraulic pressing is further compacted and cured using a
hot press at 150oC with different processing pressures: 10,
20, 40, and 60 tons of compression molding pressure for 5
minutes. Results shown that hardness and compressive
strength is higher for the composite which is pressed
under 60 tons of compression and wear rate is low for the
same. Based on the mechanical and wear properties, this
research indicated that palm slag can be used effectively
as an alternative to other fillers in brake pad composites.
The compactness of the palm slag brake pad composite, a
result of the processing compression load, plays an
important role in enhancing the mechanical and wear
properties of the product.
A.O.A. Ibhadode et-al[4] used palm kernel shells (PKSs), an
agro waste material as friction lining material for the
application of brake pads. Among other agro wastes like
hyphaene thebaica kernel shell (HTKS); and deleb palm
kernel shell (DPKS) PKS shown better performance after a
series of tests. The mechanical and physical properties
compare well with commercial asbestos-based friction
lining material. Its performance under static and dynamic
conditions compare well with the asbestos-based lining
material. However, further refinement of the PKS lining
formulation is recommended in order to have a
comparable wear rate at higher vehicular speeds.
IDris et-al [5] produced a new brake pad using banana
peels waste to replaced asbestos and phenolic resin as a
binder was investigated. The resin was varying from 5 to
30 wt% with interval of 5 wt%. Morphology, physical,
mechanical and wear properties of the brake pad were
studied. The results shown that compressive strength,
hardness and specic gravity of the produced samples
were seen to be increasing with increased in wt% resin
addition, while the oil soak, water soak, wear rate and
percentage charred decreased as wt% resin increased. The
samples, containing 25 wt% in uncarbonized banana peels
(BUNCp) and 30 wt% carbonized (BCp) gave the better
properties in all. The result of this research indicates that
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banana peels particles can be effectively used as a
replacement for asbestos in brake pad manufacture.
Poh Wah lee et-al[6] studied the friction and wear
performance of Cu-free and Sb-free environmentally
friendly automotive brake friction materials with natural
hamp fibers and geo polymers as a fraction replacement of
synthetic kevlon fibers and phenol resins respectively.
Using geopolymer in the brake materials reduced the
amount of phenol resin, which will release volatile organic
compounds (VOCs) when pads are subjected to
temperatures higher than 300oC. The Dynamometer
results shown that the modied samples had better
performance when compared to the T-baseline(Cu, Sb
based). However, the modied samples exhibit higher
wear rate than the T-baseline.
Yun Cheol Kim et-al[7] investigated the tribological
properties of phenolic resin, potassium titanate whiskers,
and cashew nut shell liquid (CNSL) cured by aldehide
using a pad-on-disk type friction tester. Mixture of aramid
pulp, rock wool, potassium titanate is used as fiber. But in
this study, only the effects of phenolic resin, potassium
titanate, and CNSL on the physical properties of the
friction material were investigated. The average
coefcient of friction is decreased when the amount of
potassium titanate is increased. Phenolic resin increased
coefficient of friction but causes for the high noise
propensity. While noise occurrence reduced by increasing
the CNSL and potassium titanate as friction material.
C.M.Ruzaidi et-al[8] investigated the development of
asbestos free brake pad composites using different fillers
(palm slag, calcium carbonate and dolomite) with phenolic
as binder, metal fiber as reinforcement, graphite as
lubricant and alumina as abrasive. Three types of
composites were prepared by compression molding of
mixture of three separate fillers. The result showed that
palm slag has significant potential to use as filler material
in brake pad composite. The wear rate of palm slag
composite was comparable with the conventional asbestos
based brake pad. The result also supported by SEM
micrograph. Palm slag and calcium carbonate (CaCO3)
brake pad composite shown better wear properties than
dolomite and comparable with the conventional asbestos
based brake pads.
M.A.Maleque et-al [9] used natural fiber reinforced
aluminum composite, coconut fibers as filler or fiber along
with aluminum composite with phenolic resin as binder.
Composite is made using powder metallurgy technique.
The better properties in terms of higher density, lower
porosity and higher compressive strength were obtained
from 5 and 10% coconut fiber composites. The
compressive strength showed the 10% coconut fiber
exhibited higher strength to withstand the load
application and higher ability to hold the compressive
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force. From the morphological study of the materials, it
was found that the coconut fibre well distributed to the
matrix and acts as filler in the friction materials.
Zhezhen fu et-al[10] developed Eco-friendly brake friction
composites which are composed of plant flax fiber,
mineral basalt fiber, and wollastonite as reinforcements,
natural graphite as solid lubricant, zircon as abrasive,
vermiculite and baryte as functional and space fillers, and
cardanol based benzoxazine toughened phenolic resin as
binder. Vermiculite acts as noise reduction agent. The
friction sample without flax fibers shows slightly higher
friction coefficient than the samples containing flax fibers
at lower temperature. Also the effect of temperature on
friction coefficient indicates that the fade phenomenon
appears at higher temperature and higher content of flax
fibers. Therefore, the optimal amount of flax fibers led to
the stable and suitable friction coefficient. It is evident that
at higher temperature, the wear resistance of friction
samples containing flax fibers was enhanced significantly
due to ductile fracture and char formation of the natural
fibers at elevated temperature.
T. Singh et al [11] designed, fabricated and characterized
the hybrid phenolic friction composites based on lapinus
aramid combination. Even though aramid pulp has
peculiar characteristics like better brillation with most of
the ingredients; ease processing aids by imparting better
pre-form green strength it loses its strength at elevated
temperatures. Lapinus/volcanic rock bre inherently
comprises of metallic-silicates(viz. mixture of SiO2 ,CaO +
MgO ,Fe2O3,Al2O3 ). It possesses good dispersion property,
reduces sensitivity to cracking and blistering during
molding/post-curing, possess heat resistant up to 1000 oC.
It uses phenolic resins of NOVLAC type as binder, barites
and graphite as other compositions. The results also
shown that the increased lapinus content with
corresponding decrease in aramid content were observed
to be effective to enhance the friction -performance, fade
performance and stability coefcient of the friction
composites, however wear performance, recovery
performance, friction uctuations and variability in
friction coefficient get deteriorates.
Kunal singha [12] reviewed on basalt fiber as it is now
being a popular choice for the material scientist for the
replacement of steel and carbon fiber. Industrial
production of basal fibers on basis of their new
technologies made its cost equal or even less than the
glass fiber. Basalt originates from volcanic magma and
flood volcanoes, a very hot fluid or semi fluid material
under the earth's crust, solidified in the open air. Chemical
composition of basalt rock contains oxides of Si, Mg, Al, Fe,
Na, K, Ti, Mn, Cr etc. Due to its high temperature resistance
it can be used as substitute for asbestos in brake pads. If
acidity modulus Ms >1.5 then it is called rock wool fiber.
Basalt fiber possesses low weight to strength ratio, better
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abrasion resistance, hardness, thermal properties but poor
bending property. Comopsites can be made by using basalt
fiber.
Arnab Ganguly et al [13] prepared new composite material
consists of phenolic resin along with epoxy resin as
tougheners to overcome the brittle nature which is caused
by phenolic resin. Graphite and silica flour are added to act
as anti-wear additives and the addition of silicone resins
acts as a fire retardant. The cashew nut resin is added to
improve the temperature resistance of the composite. The
composite synthesized was characterized using SEM
(scanning electron microscopy) technique. The samples
were subjected to a number of tests including a wear test,
thermo gravimetric analysis. It was also found to exhibit
exemplary friction and anti-wear characteristics along
with providing high temperature stability. The
constituents used in the composite are extremely
economical and are hence appropriate for industrial
applications.
P.V.Gurunath et al[14] used newly developed resin in
brake pad materials due to phenolics suffer from serious
drawbacks and limitations such as evolution of noxious
volatiles (viz. NH3(ammonia), HCHO(formaldehyde), etc.)
during ambient temperature curing, very short shelf life.
Results are compared with the resin that is capable of heat
induced ring opening polymerization is made in the
laboratory with the traditional Novalc phenolici resin., it
was concluded that the composites based on newly
developed resin showed superior performance to the
composite based on traditional phenolic resin. These
features, however, reflect the performance of materials in
severe operating conditions where surface temperature of
pads may exceed 400oC. It indicated large potential to
replace the commercially used phenolic resins. The
laboratory scale preparation studies also indicated the
cost of synthesis of the new resin is comparatively lower
than the phenolics. During the experiment they noted that
there is no correlation between strength properties of
resins, composites and their wear behavior.
3. EXPERIMENTAL PROCEDURE
3.1Preparation of the raw materials:
Agricultural wastes that are available cannot be directly
used for final application in brake pad formulation. So
some chemical and mechanical treatments are necessary
before using them in brake pad composition. Here are
some treatments presented for natural fibers based up on
the literature.
1.Palm kernel fibers[1]: Palm kernel bers (PKFs) were
collected and suspended in a solution of caustic soda
(sodium hydroxide) for twenty four hours to remove the
remnant of red oil left after extraction. The bres were
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then washed with water to remove the caustic soda and cross head of the UTM, and the load was applied at a cross-
sun dried for one week. The dried PKFs was grounded into head speed of 5 mm/min. The load at which failure
powder form using a Hammer mill and was thereafter occurred was used to calculate the compressive strength
sieved using sieve size <100 m aperture. of the sample. The Rockwell type E hardness values of the

2. Banana peels[5]: The banana peels was dried and ball Table -1: Material content (% wt) in the brake pad
mill at 250 rpm to form banana powder (uncarbonized,
BUNCP). The powder was packed in a graphite crucible Materials Formulatio Formulatio Formulatio
and red in electric resistance furnace at temperature of n1 n2 n3
1200oC to form banana peels ash (carbonized, BCp).
Phenolic 20 20 20
3.Coconut fibers[9]: Four different combinations (such as Resin
BP1, BP2, BP3 and BP4) were prepared with varying Palm slag 40 -- --
coconut fibre contents from 0, 5, 10 and 15 volume CaCO3 -- 40 --
fraction along with binder, friction modifiers, abrasive Dolamite -- -- 40
material and solid lubricant using powder metallurgy
technique for the development of natural fibre reinforced
Graphite 10 10 10
aluminium automotive brake pad materials. The coconut Steel 20 20 20
fibre was used as a filler material. This was collected from fiber
waste coconut fruit and cleaned thoroughly using ethanol Alumina 10 10 10
to remove impurities. It was crushed and ground to a fine composite [13]
powder (with a range of 100-200 m), and sieved using
crusher machine.

4. Flax fibers[10]:Flax fibers were treated by drying at

80C for 30 min, 12% NaOH solution at room temperature
for 1 h, and 1M HCl steam for 30 min.

Aramid fibers, lapinous fibers[11], basalt fibers[12] etc

can be directly used for formulating the brake pad
composite without any chemical treatment.

3.2Preparation of the Brake pad composite:

Once the chemical treatment and mechanical treatment
for raw materials is over, the final composition is made
with other ingredients like filler, fiber, binder, frictional
additives etc in different formulations. A sample
formulation for palm slag wastes is shown in Table 1. Each
formulation is mixed to obtain a homogeneous mixture of
ingredients. Then, the mixtures are compacted at a
pressure of 15-17 MPa using a unaxial, hydraulic hand-
press machine for the green body of the brake pad
composite Then, the green body was compacted further
and cured using a hot press at 150 C with 60 tons of
compressive molding pressure for five minutes. At the end
of the hot-pressing process, samples were taken out of the
molds, allowed to cool to room temperature, and cured
further at a constant temperature of 150 C in air oven for
four hours [13]. Final brake pads are as shown in Figure 1.
3.3 Testing and Analysis:
The mechanical properties of phenolic resin based brake
pad composites were determined by a universal testing
machine (UTM) at room temperature. Each sample,
consisting of an initial cross-sectional area of 86.6 mm,
was placed between the lower cross member and lower
Figure 1 Sample brake pad after final finishing
friction composite samples were obtained using a digital
Rockwell hardness tester. A sample with a diameter of 10
mm was used to carry out the test at different filler. The
test was conducted using a 1/8-inch-diameter steel ball
indenter with a load of 100 kgf[13]. Brake pad test rig was
used to determine the pads wear, disk temperature rise
and disk stopping time. Figure 2 shows the schematic
diagram of the brake pad test rig. It has a 2.2kW motor
with a provision for speed variation by using a stepped
pulley. The motor provides the energy required to set the
flywheel weights and the brake disc in angular motion.
When a set of brake pad is fixed into the brake caliper
assembly of the test rig, the system is switch-on and the
drive shaft begins to rotate, it is then allowed to attain a
desired speed. Thereafter, a manual force is applied on the
brake pedal which is similar to that of a motor car.
Subsequently the stopping time, temperature of the disc
and brake pad material lost are recorded. The speed and
brake line pressure ranges were: 6.66 m/s to 13.82 m/s
and 0.2 0.6 MPa respectively for the test conditions [4].

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 International Research Journal of Engineering and Technology (IRJET)
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Figure 2: Schematic representation of the Brake pad test
rig [4]
4. RESULTS AND DISCUSSIONS
4.1 Density and porosity of brake pad composite with
coconut fibers [9]:
A density measurement test has been carried out on a
laboratory scale to examine the density of the material
after sintering. Density is depends upon the ingredients in
the pad material. A metallic element will have a higher
density than an organic element. Friction elements often
exist in combination of various elements. The results
shown in Figure 3 are the average density of three
readings for each formulation. It is seen from Figure 3 that
the density of the 15 % coconut fibre(BP4) composite
shows lower than 0% coconut fibre(BP1) which have
more coconut fibre. However, formulation BP1 has better
properties because of having higher density with the value
of 2.176 g/cm. This formulation has no coconut fibre in
its constituents, hence, shows higher density of this
composite material. The formulation, BP2 shows the
second highest density with the value of 2.099 g/cm.
Figure 3: Density of materials
Figure 4 shows the porosity test results for all formulations
of brake pad materials. Porosity plays an important role in
automotive brake pad materials .The function of porosity is
to absorb energy and heat. This is a very important for the
effectiveness of the brake system. Theoretically, lower
porosity will result in higher friction coefficient and wear
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rate due to higher contact areas between the mating
surfaces. Brake pad should have a certain amount of
porosity to minimize the effect of water and oil on the
friction coefficient and increasing porosity by more than
10% could reduce the brake noise. Porosity, a gross
measure of the pore structure, gives the fraction of total
volume which is void. The pore structure should be
preserved during specimen grinding and polishing.
Distortion by excess working will smear material over the
pores, giving the appearance of a low porosity (German,
1997). From the porosity results as shown in Figure 4 it
can be seen that two brake pad formulations such as, 5 and
10 % of coconut fibre composite shows lower percentage
of porosity compared to other two.
Figure 4: Porosity of materials
4.2 Effect of phenolic resin on properties of the
brake pad with banana peels [5]:
As the weight fraction of resin increased wear rate
decreases in the banana peels particles. This may be
attributed to higher/ closer packing of the microstructure
which has affected stronger bonding of banana peels with
resin. Also due to high hardness values and compressive
strength of the samples as the resin addition increased in
the banana peels particles (Blau,2001; Aigbodion and
Akadike, 2010). The coefcient of friction of the samples
increases as the wt% of resin increased in the formulation.
Again the effect of uncarbonized banana peels particles
shows a marked effect as higher friction was recorded for
brake pad composites as the wt% of resin increased. The
friction co-efcient fall within the industrial standard
ranges of 0.3 0.45 for automotive brake pads system
(Dagwa and Ibhadode, 2005). The results of this work
indicates that sample containing 25 wt% in BUNCp and 30
wt%BCp gave better properties than other samples tested.
Hence, the increase in wt% of resin in the banana peels
particles, the better the properties. These grade of results
were compared with that of commercial brake pad
(asbestos based) and optimum formulation laboratory
brake pad (Palm Kernel Shell based (PKS) and bagasse as
shown in the Table 2 which were tested under similar
conditions
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Table 2 :Properties of different agricultural wastes fibers

for brake pad composites [5] REFERENCES

Propert Comm Labora Labora New New [1] K.K. Ikpambese, D.T. Gundu, L.T. Tuleun Evaluation of
ies ercial tory tory Laborat Labora palm kernel bers (PKFs) for production
Brake Formul Formul ory tory of asbestos-free automotive brake pads February 2014.
pad ation ation Formul Formul
(asbest (Palm (bagas ation ation [2] C. M. Ruzaidi, H. Kamarudin, J. B. Shamsul, M. M. A.
os Kernel se) (banana (banan Abdullah Comparative Study on Thermal, Compressive,
based) Shell) peels a peels and Wear properties of Palm Slag Brake Pad Composite
uncarbo carbon with Other Fillers, Advanced Materials Research Vols. 328-
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resin) resin) [3] C. M. Ruzaidi, H. Kamarudin, J. B. Shamsul, M. M. A.
Specific 1.89 1.65 1.43 1.26 1.20 Abdullah, Rafiza Mechanical Properties and Wear
gravity Behavior of Brake Pads Produced from Palm Slag,
(g/cm3 Advanced Materials Research Vols. 341-342 (2012) pp 26-
) 30
Wear 3.80 4.40 4.20 4.15 4.67
rate [4] A. O. A. Ibhadode, I. M. Dagwa, Development of
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Frictio 0.3-0.4 0.440 0.420 0.40 0.35
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coeffici 2013. Ecofriendly asbestos free brake-pad: using banana
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5. CONCLUSIONS [8] C.M. Ruzaidi, H. Kamarudin, J.B. Shamsul, A.M. Mustafa

In this review paper different agricultural wastes are
studied as alternative for asbestos brake pads. The results
are shown that the performance is almost equal to
asbestos brake pads without any environment and health
effects. Chemical and mechanical treatments of raw
materials for using them in formulation are presented. For
having better physical properties, brake pads with coconut
fibers are studied and their composition percentage is
optimized. Increasing the percentage of phenolic resin to
the composition made up of banana peels increases
tribological properties but excessive addition causes poor
shelf life, evolution of noxious volatiles etc. Alternatives
for phenolic resins like newly developed resin, epoxy resin
etc are studied
Al Bakri, , J. Liyana,Mechanical Properties and Morphology
of Palm Slag, Calcium Carbonate and Dolomite Filler in
Brake Pad Composites, Applied Mechanics and Materials
Vols. 313-314 (2013) pp 174-178
[9] M.A. Maleque, , A. Atiqah, R.J. Talib and H. zahurin,
New natural fibre reinforced aluminium composite for
automotive brake pad, (IJMME), vol. 7 (2012), no. 2, 166-
170.
[10] Zhezhen Fu, Baoting Suo, Rongping Yun, Yimei Lu, Hui
Wang, Shicheng Qi,Shengling Jiang And Yafei Lu,
Development of Eco-Friendly Brake Friction Composites
Containing Flax Fibers,
http://hdl.handle.net/10084/94936 , 31/07/2012.

[11] T. Singh,A. Patnaik, Performance assessment of

lapinusaramid based Brake pad hybrid phenolic

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composites in friction braking,ACME 191,January, 2014 BIOGRAPHIES

www.sciencedirect.com.
Dr.R.Umamaheswara Rao
[12] Kunal Singha A Short Review on Basalt Fiber , presently working as Associate
International Journal of Textile Science 2012, 1(4): 19-28 professor in GMR Institute of
DOI: 10.5923/j.textile.20120104.02. Technology(Autonomous),Rajam
Email: umr_r@yahoo.co.in
[13] Arnab Ganguly , Raji George, Asbestos Free Friction
Composition For Brake Linings Bull. Mater. Sci., Vol. 31,
No. 1, February 2008, Pp. 1922. Indian Academy G.Babji pursuing M.Tech
Of Sciences. (Thermal Engineering) in GMR
Institute of
[14] P.V. Gurunath, J. Bijwe ,Friction and wear studies on Technology(Autonomous),Rajam.
brake-pad materials based on newly developed resin, Email:mechbab.8@gmail.com
Wear 263 (2007) 12121219.

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